Beam with torsional deformation and multi-geometry cross-section

ABSTRACT

A beam configured to couple to a vehicle includes end areas comprising end midpoints that are equidistant from a top face and a bottom face on a vertical axis when the beam is positioned on a vehicle, and a central area positioned between the end areas, the central area having a central area midpoint that is equidistant from the top face and the bottom face on the vertical axis when the beam is positioned on a vehicle and that is positioned in the center of the beam along the longitudinal axis. The longitudinal axis of the beam passes through the end area, wherein the central area is capable of rotating about the longitudinal axis when the beam is impacted by an applied force.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of Non-Provisional U.S.application Ser. No. 15/748,199 filed Jan. 29, 2018, which is a 371 ofInternational Application No. PCT/IB2016/054583, filed Jul. 29, 2016,which claims priority to U.S. Provisional Application No. 62/199,279filed Jul. 31, 2015, which are incorporated herein by reference in theirentirety.

BACKGROUND

Bumper systems for automotive vehicles can include a beam that extendswidthwise across the front or rear of a vehicle and that can be mountedto rails that extend in a lengthwise direction and optionally an energyabsorber.

Bumper systems can include a fascia for covering the beam and/or energyabsorber. There are many specifications and regulations which a bumpersystem can be subjected, including regional safety specifications andstandards and internal development specifications, such as spatialconstraints and weight limitations. Bumper systems that are lightweightare in demand to current vehicle styling trends.

To meet today's vehicle styling trends, there exists a need for bumpersystems that are lightweight and capable of performing within desiredspecifications, standards, and regulations. Traditional bumper systemsdo not address these needs.

SUMMARY

Disclosed, in various embodiments, are lightweight beams that can beused in bumper assemblies and related methods.

A beam configured to couple to a vehicle, comprises: a first end areacomprising a first end midpoint equidistant from a top face and a bottomface on a vertical axis when the beam is positioned on the vehicle; asecond end area comprising a second end midpoint equidistant from thetop face and the bottom face on the vertical axis when the beam ispositioned on the vehicle; a central area positioned between the firstend area and the second end area, the central area having a central areamidpoint that is equidistant from the top face and the bottom face onthe vertical axis when the beam is positioned on the vehicle 38 and thatis positioned in the center of the beam along a longitudinal axis; aninner surface; and an outer surface; wherein the longitudinal axis ofthe beam passes through the first end area and the second end area;wherein the central area is capable of rotating about the longitudinalaxis when the beam is impacted by an applied force.

A beam configured to couple to a vehicle, comprising: a first end areacomprising a first end midpoint equidistant from the top face and thebottom face on a vertical axis when the beam is positioned on thevehicle; a second end area comprising a second end midpoint equidistantfrom the top face and the bottom face on the vertical axis when the beamis positioned on the vehicle; a central area positioned between thefirst end area and the second end area, the central area having acentral area midpoint that is equidistant from the top face and thebottom face on the vertical axis when the beam is positioned on thevehicle; wherein the longitudinal axis of the beam passes through thefirst end area and the second end area, and optionally a fasciapositioned to substantially envelop the beam; wherein a cross-section ofthe beam taken along a line from the inner surface to the outer surfacevaries along the length of the beam.

BRIEF DESCRIPTION OF THE DRAWINGS

The following is a brief description of the drawings, wherein the likeelements are numbered alike and which are presented for the purposes ofillustrating the exemplary embodiments disclosed herein and not for thepurposes of limiting the same.

FIG. 1 is an isometric view of an embodiment of a bumper beam.

FIG. 2 is a front view of the beam depicted in FIG. 1.

FIG. 3 is a front view of an embodiment of a beam.

FIG. 4 is a cross-sectional view of an embodiment of a bumper system.

FIG. 5 is an isometric view of an embodiment of a bumper beam.

FIG. 6 is a cross-sectional view of an embodiment of a bumper system.

FIG. 7 is an isometric view of an embodiment of a bumper beam.

FIG. 8 is a perspective view of a bumper system assembled onto avehicle.

FIG. 9 is an exploded view of the bumper system of FIG. 1.

FIG. 10 is an isometric front view of an underrun protection device.

FIG. 11A is a top perspective view depicting the position of a pendulumin an ECE R 42 center pendulum impact test.

FIG. 11B is a top perspective view depicting the relative position of apendulum in an ECE R 42 outboard pendulum impact test.

FIG. 11C is a top perspective view depicting the position of a pendulumin an ECE R 42 corner pendulum impact test.

FIG. 12A is a graphic illustration of force versus time in a centerpendulum impact test.

FIG. 12B is a graphic illustration of fascia intrusion versus time in acenter pendulum impact test.

FIG. 13A is a graphic illustration of force versus time in an outboardpendulum impact test.

FIG. 13B is a graphic illustration of fascia intrusion versus time in anoutboard pendulum impact test.

FIG. 14A is a graphic illustration of force versus time in a cornerpendulum impact test.

FIG. 14B is a graphic illustration of fascia intrusion versus time in acorner pendulum impact test.

FIG. 15 is a graphical illustration of results of a RCAR 40% overlapimpact test.

DETAILED DESCRIPTION

Disclosed herein, in various embodiments, are beams for bumper systemsthat can be used in automotive vehicles, for example as a component of amulti-part vehicle bumper system. The beams of the present disclosurecan be lightweight and can have increased stiffness, and can utilizeless packing space than a bumper system comprising a metal bumper beamwith an energy absorber in front of the beam, between the beam and afascia. The beams and bumper systems including the beams disclosedherein can also reduce the damage incurred by a vehicle in avehicle-to-vehicle or vehicle-to-impactor impact such that the bumpersystems can enable the vehicle to meet low speed vehicle damageabilitystandards.

Bumper systems incorporating beams of the present disclosure can conformto desired space constraints while meeting ECE-42 and/or R-CAR standardsand specifications. The Research Council for Automobile Repair (herein“R-CAR”) test program is used by several test houses in Europe, Asia,and South America and specifies that front and rear bumper systems of avehicle meet certain criteria under standardized test conditions. R-CARassessment of bumper performance is aimed at encouraging manufacturersto design bumper systems that meet a variety of goals, including systemsthat protect vehicle corners at low speed impact and that have desirableenergy absorption. The R-CAR test impacts the bumper member with a solidbarrier at a designated speed and seeks a non-destructive bending of thebumper beam along with prevention of damage to the underlying vehicle.In addition, bumper systems can be subject to the Economic Commissionfor Europe Regulation Number 42 (“ECE-R42”), which specifies that acar's safety systems should continue to operate normally after the carhas been impacted by a pendulum or moving barrier under simulatedcollisions at certain speeds and at certain locations on the bumperassembly. It has been discovered that in order to satisfy RCAR andECE-R42 criteria, a rear beam having high stiffness at the corners andhigh stiffness in the center can be desirable.

Bumper systems including beams of the present disclosure can satisfyR-CAR, including for example low speed damageability insurance testssuch as R-CAR Section 0031, and/or ECE-R42 criteria, such as low speeddamageability regulation ECE-42 Section 0031. In an embodiment, a bumpersystem including a beam of the present disclosure can absorb a cornerimpact at 2.5 kilometers per hour (kph) when coupled to a vehicleweighing 500 to 2,000 kilograms (kg), for example, 900 to 1,600 kg, withan intrusion of less than or equal to 140 millimeters (mm), whereintrusion refers to the amount the beam intrudes into the passengercompartment of the vehicle. The beams of the present disclosure can havehigher stiffness than conventional beams, and can have lower levels ofintrusion. In an embodiment, a bumper system including a beam of thepresent disclosure can absorb a center pendulum impact at 4 kph whencoupled to a vehicle weighing 500 to 2,000 kg, for example, 900 to 1,600kg, with an intrusion of less than or equal to 140 mm. In an embodiment,a bumper system including a beam of the present disclosure can absorb anoutboard impact at 4 kph when coupled to a vehicle weighing 500 to 2,000kg, for example, 900 to 1,600 kg, with an intrusion of less than orequal to 140 mm.

Turning now the figures, FIG. 1 is an isometric view of a beam 10. Thebeam 10 can include a top face 11 and a bottom face 12, each faceextending along a longitudinal axis x (e.g., horizontal axis) of thebeam 10. The bottom face 12 is oriented toward the road when the bumperis assembled onto a vehicle. The beam further includes an inner surface13 oriented toward the vehicle and an outer surface 14 disposed oppositethe inner surface 13 (i.e., away from the vehicle, oriented toward afascia). The inner surface 13 can have a greater total solid surfacearea than the outer surface 14.

The beam 10 can include two end areas 20 and a central area 21 disposedbetween the two end areas 20. The end areas 20, when the beam 10 ispositioned on a vehicle, can be approximately the same size andapproximately the same distance from the road. The beam 10 can include aplurality of ribs 22. As shown in FIG. 1, the plurality of ribs 22 canextend between the inner surface 13 and the outer surface 14, and can beoriented horizontally, vertically, or diagonally. Ribs 22 can bepositioned such that they are parallel, perpendicular, or diagonal tothe outer surface 14. Optionally, the ribs 22 can intersect other ribs22. A stiffness of the beam 10 can be tailored to meet various standardsdepending upon several variables, such as the number of ribs, thethickness of ribs, and the type of material. Edges of the ribs 22 canform part of an edge of the beam 10, such as a part of the inner surface13, or the outer surface 14.

The inner surface 13 can vary in relative position along the horizontalaxis, x, of the beam 10. The inner surface 13 can vary in relativeposition along a vertical axis, y, of the beam 10. The end areas 20 ofbeam 10 can be positioned such that they are disposed closer to thevehicle than the central area 21. In other words, the central area 21can be located further from the vehicle than either or both of the endareas 20. The beam 10 can optionally include transition areas 30 betweenthe end areas 20 and the central area 21. Transition areas 30 can becurved or angled relative to the longitudinal axis, x, such that thecentral area 21 can be oriented closer to the ground than the end areas20. Transition areas 30 can be curved or angled relative to thelongitudinal axis, x, such that the central area 21 can be oriented adistance from the vehicle that is larger than the end areas 20. Asillustrated in FIG. 1, the central area 21 is located further from thevehicle than end areas 20. However, it is to be understood that only aportion of the central area 21 can be located further from the vehiclethan end areas 20 in the horizontal axis, x, or the vertical axis, y.For example, greater than or equal to 20% of the central area 21 can belocated further from the vehicle than the end areas 25 in the horizontalaxis, x, or the vertical axis, y, for example, greater than or equal to50%, for example, greater than or equal to 75%, for example, greaterthan or equal to 85%, for example, greater than or equal to 90%, forexample, greater than or equal to 95%, for example, greater than orequal to 99%. At the central area 21, the top face 11 can be planar orcurved. At the central area 21, the bottom face 12 can be planar orcurved. In some embodiments, top face 11 is planar in at least a portionof central area 21. In some embodiments, bottom face 11 is planar in atleast a portion of central area 21. A leg 19 on the edge areas 31 can beoriented at an angle away from the central portion 18 of end areas 20.For example, the angle, α, can be 0 to 180 degrees relative to thelongitudinal axis, x, of the beam 10. For example, the angle, α, can be0 to 90 degrees.

During a collision, an impact force, F, can be applied to beam 10. Uponapplication of an impact force, F, the beam 10 can absorb energy througha crushing activity in a direction toward a vehicle, D. The beam 10 canabsorb energy through a twisting activity by movement in a rotationaldirection, R when an impact force, F, is applied to the beam, 10. Thebeam 10 can absorb energy through a crushing activity in a directiontoward a vehicle, D, and through twisting activity by movement in arotational direction, R, when an impact force, F, is applied to the beam10.

During a collision, an impact force can be applied directly orindirectly to the outer surface 14 of the beam 10. The beam 10 canabsorb energy through a crushing action as the beam 10, at least inpart, is moved toward the vehicle. The impact force can be appliedindirectly to the beam 10 through fascia 34. An impact force load can beapplied at various locations along the horizontal axis, x, of the beam.For example, an impact force can be applied to the central area 21, anend area 20, a transitional area 30 as depicted, for example, in FIG. 1,or a combination comprising at least one of the foregoing. When animpact force is applied, the beam 10 can absorb energy of the impactthrough one or more mechanisms. For example, when the central area 21 isimpacted, the beam 10 can absorb energy through a crushing action, inwhich one or more areas of the beam 10 are moved toward the vehicle indirection D. In such an impact, the beam 10 may or may not experiencedeformation. In an embodiment, the beam 10 can advantageously absorbenergy through torsion, as the central area 21 of the beam 10 rotatesabout the longitudinal axis, x, of the beam 10 in direction R when thebeam is impacted by an impact force. For instance, the central area 21can display a crushing motion and a twisting motion when an externalforce is applied to the beam 10, such as when a force is applied to thecenter of a beam through a fascia. In an embodiment, after the appliedforce is removed, the beam 10 can return to its original configuration.In one embodiment, the central area 21 of the beam 10 is verticallyoffset and the beam 10 can absorb energy through torsion. In anembodiment, the central area 21 of the beam 10 is vertically offset andthe beam 10 can absorb the energy through torsion and through crushing.

FIG. 2 is a front view of the beam depicted in FIG. 1. The beam 10 canhave a length, L and a width, W. As shown in FIG. 2, width, W can beuniform across the length, L of the beam 10. For example, central area21 and end areas 20 can have the same width. It is also contemplatedthat the width, W can vary across the length, L of the beam 10. Forexample, central area 21 and end areas 20 can have different widths. Forexample, central area 21 can have a varying width across a length ofcentral area 21. For example, end areas 20 can have a varying widthacross a length of end areas 20. Length L and width W can be selectedbased upon the desired performance characteristics of the bumper system.For example, the width of a beam can be greater than or equal to 50millimeters (mm). The width W can be 50 to 300 mm. The width W can be100 to 200 mm. The width W can be 100 to 150 mm. Length L can be anydesired length for a beam in a bumper system in a particular vehicle.For example, the length L can be greater than or equal to 1,000 mm, forexample, 1,300 mm.

As previously described herein, the beam 10 can include a central area21 that can be vertically offset from the end areas 20. As shown in FIG.1, the transition areas 30 can direct the beam 10 at an angle, α, sothat the central area 21 can be vertically displaced from the end areas20. Top edge 11 can be vertically higher or lower at the central area 21than at the end areas 20 by offset distance Δ.

The central area 21 can include a central area midpoint 32 located inthe middle of the beam both horizontally and vertically. The end areas20 can contain one or more end area midpoints 33 located equidistantfrom the top face 11 and bottom face 12 of the beam 10. As illustratedin FIG. 2, in a beam 10 including a central area 21 vertically offsetfrom the end areas 20, the central area midpoint 32 can be located at apoint on the beam 10 that is lower than the end area midpoints 33. It iscontemplated, however, that the central area midpoint 32 can be locatedat a point on the beam 10 that is higher than the end area midpoints 33.The vertical distance between the end area midpoints 33 and the centralarea midpoint 32 can be equal to the offset distance Δ, or can beanother value. The offset distance Δ can desirably be, for example,greater than or equal to 50 mm, for example the offset distance Δ can begreater than or equal to 75 mm and less than or equal to 500 mm. Forexample, in a beam having a length of 1,282 mm and a width of 110 mm,offsetting the central area a distance of 75 mm relative to thelongitudinal plane of the end areas can impart increased stiffness inthe same deformation space relative to a beam with a vertical offsetless than that described herein or an offset distance equal to zero. Theoffset distance can be to 1 to 4 times the width of the beam, forexample, 2 to 4 times the width of the beam, for example, 3 to 4 timesthe width of the beam. In some embodiments, a beam can comprise morethan one vertical offset.

The cross-sectional area taken across the A-B plane, i.e., thecross-section taken along a line from the inner surface 13 to the outersurface 14 depicted in FIG. 1, may or may not vary along the length ofthe beam 10.

FIG. 3 illustrates a beam 10 where the central area 21 is not verticallyoffset. In FIG. 3 a beam 10 with length L and central area midpoint 32is shown. Beam 10 includes a central area 21 and two end areas 20. InFIG. 3, the central area 21 is not vertically offset from the end areas20. As can be seen in FIG. 3, the beam width can be approximatelyuniform across the length L of the beam 10.

It is to be understood that the central area 21 can have an innersurface 13 spaced apart a distance from a vehicle, whether or not thecentral area 21 is vertically offset from the end areas.

Also disclosed herein is a bumper system 40 including a beam 10, andoptionally a fascia 34. FIG. 4 depicts a beam 10 in cross-section takenin a line from the inner surface 13 to the outer surface 14 (across theA-B plane illustrated in FIG. 5). As is seen in FIG. 4, beam 10 can beadjacent to a fascia 34, which can envelop the beam 10 when assembledonto a vehicle as part of a bumper system 40. In a collision, an impactforce can be applied directly to fascia 34.

The beam 10 can form one or more geometric patterns when viewed in across-section taken along a line from the inner surface 13 to the outersurface 14 (across the A-B plane illustrated in FIGS. 5 and 7). Forexample, FIG. 4 illustrates a bumper system 40 including a beam 10having an exemplary box shaped geometric pattern, or a box section 35.The cross-sectional area of the beam 10 across the A-B plane has a boxsection 35 to assist in absorbing kinetic impact energy and impartingstiffness as the impact energy is transferred through the fascia 34 andbeam 10 toward the vehicle. The box section 35 can include a patternthat can be formed from ribs 22 extending between a top face 11, and abottom face 12 and between the inner surface 13 and the outer surface 14and can include a series of horizontal and vertical planes. The boxsection 35 can be formed from a sheet of material (e.g., a single sheetof material), such that it contains a series of angles β of 45 to 135degrees when viewed across the A-B plane, for example, including anangle β of approximately 90 degrees. Angle β as illustrated in FIG. 4can be the same or can be different from one another in any given boxsection 34. The box section 35 can be of rectangular or square shape,for example the box section 35 can form a series of rectangular shapesas depicted in FIG. 4. The box shape 35 can be of square shape, or ofanother shape that is substantially rectangular or square, such as atrapezoidal shape or a parallelogram shape. A box section 35 can includetwo or more rectangular shapes or square shapes stacked on top of oneanother, wherein the rectangles and/or squares are open on one side whenviewed in cross-section.

Any number of openings on either the inner surface 13 or outer surface14 is contemplated. For example, as illustrated in FIG. 4 a box section35 when viewed in cross-section can have three openings on the innersurface 13 and two openings on the outer surface 14. As illustrated inFIG. 6, for example, a box section 35 can have two openings on the innersurface 13 and three openings on the outer surface 14. The box section35 can have open ends that alternate across the A-B plane, such that abottom rectangle can have an open end on the inner surface 13 and therectangle immediately above the bottom rectangle can have an open end onthe outer surface 14. It is to be understood that the size andorientation of the box section 35 can be tailored to meet desiredproperties. It can be possible to form a section, such as a box section,with a single sheet of material, such as a sheet of thermoplasticmaterial, molded to form the desired geometrical pattern. It can also bepossible to form a section, such as a box section, with multiple sheetsof material, thereby creating a multiwall sheet. A beam 10 incorporatinga box section 35, can absorb energy through torsion, deformation,crushing or a combination comprising at least one of the foregoing. Thebox section 35 can absorb energy through a combination of torsion anddeformation.

The beam can include a box section 35 in the central area 21. The beam10 can include a box section in end areas 20. The beam 10 can include abox section in transition areas 30. Beam 10 can include a box section 35and a central area 21 that does not include a vertical offset.

FIG. 5 is an isometric view of a beam 10 including a central area 21,transition areas 30, and end areas 20. The beam 10 can include an innersurface 13 and outer surface 14. As illustrated in FIG. 5, beam 10 caninclude ribs 22 disposed in the central area 21, in the transition area30, and in the end area 20.

As shown in FIG. 1 and FIG. 7, for example, the end areas 20 can includeribs that do not form a box section 35 with open ends that alternateacross the A-B plane. As is shown in FIG. 1, for instance, the end areas20 of the beam 10 can, for example, include a series of ribs 22 thehorizontal and vertical axes that form a series of boxes with openingsfacing the outer surface 14 and not alternating with openings on theinner surface 13. It is to be understood that beam 10 can include ribs22 or other supports in addition a box section 35 or triangular section36. For example, beam 10 can include ribs 22 that form vertical planesthat can provide structural support to the horizontal planes of boxsection 35.

In an embodiment of the invention, a cross-sectional area of the beamacross the A-B plane (see FIG. 5 and FIG. 7) can include a combinationof geometrical patterns. FIG. 6 is a cross-sectional view taken acrossthe A-B plane of the beam 10 depicted in FIG. 7. As shown, thecross-sectional area in the central area can have an inner surface 13,an outer surface 14, a box section 35 and a triangular section 36. Theinner surface 13 can vary in relative position along the longitudinalaxis x and/or the vertical axis y of the beam 10. For example, the innersurface 13 can be spaced further from the vehicle at the central area 21than at the end areas 20. The outer surface 14 in the central area 21can be approximately the same distance from the vehicle as the outersurface 14 in the end area 20. The triangular section 36 can include atriangle shape having an open face 37 directed toward fascia 34. Thetriangular section 36 can include at least one angle y adjacent to a boxsection 35. The angle γ can be less than 90 degrees. Ribs 22 can bedispersed between triangular section 36 and box section 35 such that atriangular section and box section can share at least one edge. Asillustrated in FIG. 6, a beam 10 can include one triangular section 36and one box section 35. It is contemplated, however, that a beam 10 caninclude more than one triangular section 36 and/or more than one boxsection 35.

Turning back to FIG. 4, the box section 16 can include a series ofhorizontal planes that are angled at approximately 90 degrees relativeto one or more adjacent vertical planes when viewed across the A-Bplane. In some embodiments, the planes can be angled at greater than 90degrees or less than 90 degrees. For instance, box section 16 caninclude sections in the shape of squares, rectangles, parallelograms,trapezoids, or a combination comprising at least one of the foregoingwhen viewed across the A-B plane. Such shapes can have one or more opensides or may be closed on all sides by the beam planes.

Turning to FIG. 6, the triangular section 36 can include at least oneangle that is less than 90 degrees and is adjacent to and/or attached tothe box section 35. The triangular section 36 can form a part of the topface 11 of the beam 10, while the box section 35 can form a part of thebottom face 12 of the beam 10. The triangular section 36 can appear incross-section when viewed across the A-B plane as an open endedtriangle, wherein the open end is on and/or forms part of the outersurface 14 of the beam 10. A combination of a box section 35 and atriangular section 36 can be present in a central area 21, a transitionarea 30, an end area 20, or a combination comprising at least one of theforegoing. A beam 10 can include varying cross-sectional geometricpatterns along the length of the beam. For example, a beam can include acombination box sections 35 and triangular sections 36 at one pointalong a horizontal axis and can include a box section 35 with notriangular section 36 at another point along the horizontal axis. Forinstance, a beam 10 can include a central area 21 with a combination boxsection 35 and triangular section 36 and a transition area 30 and/or endarea 20 including a box section. In another example, the central area 21can include one or more cross-sectional areas with a combinationtriangular 36 and box section 35 and one or more cross-sectional areasincluding a box section 35 with no triangular section 36. As usedherein, the phrase “combination of a box section and a triangularsection” means a geometrical pattern viewed across the A-B planeincluding a box section 35 and a triangular section 36. The combinationof a box section 35 and a triangular section 36 can reduce the totalweight of the beam relative to a beam of the same spatial proportionswith only a box section that does not include a triangular section.Moreover, a beam 10 including a combination of a box section 35 and atriangular section 36 can maintain the same contact area with the fascia34 as compared to a beam containing only a box section and/or can havehigh stiffness at the central area 21.

When end areas 20 do not include a triangular section. When viewed alongthe length of the beam 10, the cross-section can vary. FIG. 7 is anisometric view of an exemplary beam 10 including a combination of a boxsection 35 and a triangular section 36. As is shown, central area 21contains an outer surface 14 and an inner surface 13. Top face 11 ofcentral area 21 forms an edge of a triangular shape, and the top edge ofa triangular section 36 as depicted, for example, in FIG. 6. A boxsection 35 is included in central area 21 below triangular section 36.The box section 35 includes multiple ribs 22 and a bottom face 12 of thebeam 10. FIG. 7 also illustrates a central area 21 that has a varyingoffset distance from the inner surface 13. For example, in FIG. 7,central area 21 has a greater offset distance at a centerpoint than attransition areas 30.

Stated another way, the beam 10 can have a variable width along thelength of the beam. The beam 10 can have a larger cross-sectionalcircumference at the end areas 11 than the cross-sectional circumferencein the central area 22, for example as shown in FIG. 7.

As used herein, “width” is understood to mean the distance from the topface 11 to the bottom face 12 of the beam 10 at a particular point alongthe longitudinal axis x. The end areas 20 can have a greater width thanthe central area 21. Providing end areas 20 with greater width than thewidth of the central area 21 can provide increased stiffness and/orincreased contact area at the corner(s) of a bumper system. Suchincreased stiffness and/or increased contact area can aid in absorptionof energy when an impact force is applied to a corner of the bumpersystem. For example, increased height of the end areas can providebenefits in R-CAR testing.

The cross-section of the beam 10 taken along a line from the innersurface 13 to the outer surface 14 can vary along the length of thebeam. For example, the geometric pattern of the cross-section of thebeam 10 can vary along the length L of the beam 10 or thecross-sectional circumference can vary along the length of the beam. Thewidth W of the cross-section can vary along the length L of the beam 10.The relative vertical position of the beam 10 in the cross-section canvary along the length L of the beam 10.

FIG. 8 shows a perspective view of a front portion of a vehicle 38having a bumper system 40 according to an embodiment of the invention.Bumper system 40 includes a bumper beam 10 in which the beam 10 ismounted to side rails 42 of a vehicle 38. Bumper system 40 optionallyincludes a fascia 34.

FIG. 9 is a perspective view of a front portion of a vehicle 38 having abumper system 40 showing the connection of the bumper beam 10 attachedto side rails 42. Bumper beam 10 can attach to mounting plates 44, forexample using fasteners that mount the bumper beam 10 to receptors 46 ofmounting plates 44. Fascia 34 can be designed to integrate the bumperassembly with the vehicle body, while also improving aerodynamics toreduce wind resistance of the vehicle 38.

The beam can be lightweight. For example, the bumper beam can weigh lessthan or equal to 4 kilograms (kg), for example, less than or equal to3.5 kg, for example, less than or equal to 3 kg, for example less thanor equal to 2.5 kg. In one embodiment, a beam can weigh about 2.34 kg.

The beams disclosed herein can be disposed at a front of a vehicle or ata rear of a vehicle, for example, the beams can be front beams or rearbeams. The beams are contemplated in all types of vehicles, e.g.,passenger cars, trucks, buses, commercial trucks, etc. The beam can beattached to a passenger car. The beam can be attached to a truck (e.g.,a commercial truck or a passenger truck). The beam can be a component ofa rear bumper system of a vehicle. The beam can be a component of afront bumper system of a vehicle. The beam can be a component of a frontunderrun protection device 100 (see FIG. 10).

The beam can be made from any thermoformable material having the desiredcharacteristics. For instance, the beam can comprise a thermoplasticpolymer, a glass mat thermoplastic polymer (GMT), a thermoset, acomposite, a metallic material, or a metallic thermoplastic polymerhybrid. The preferred characteristics of the material used to form thebeam include good stiffness, high toughness/ductility, thermalstability, and high energy absorption capacity among others. Exemplarymaterials include thermoplastic polymers as well as combinations ofthermoplastic polymers with elastomeric polymers, and/or thermosetpolymers. Possible materials include acrylonitrile-butadiene-styrene(ABS); polybutylene terephthalate (PBT); polycarbonate;polycarbonate/ABS blends; copolycarbonate-polyesters;acrylic-styrene-acrylonitrile (ASA);acrylonitrile-(ethylene-polypropylene diamine modified)-styrene (AES);phenylene ether polymers; blends of polyphenylene ether/polyamide;polyamides; phenylene sulfide polymers; polyvinyl chloride (PVC); highimpact polystyrene (HIPS); low/high density polyethylene (L/HDPE);polypropylene (PP); expanded polypropylene (EPP); and thermoplasticolefins (TPO). The beam can be fabricated, for example, from steel,aluminum, or a glass mat thermoplastic polymer.

Exemplary materials include XENOY™, commercially available from SABIC'sInnovative Plastics Business. XENOY™ polymers are a thermoplastic alloyblend of polycarbonate (PC) with polyesters, polybutylene terephthalate(PBT), or polyethylene terephthalate (PET), particularly PBT. XENOY™polymers are characterized by their ductility, chemical resistance, hightemperature dimensional stability and mechanical strength. They alsooffer very good aesthetics, lubricity, UV resistance and colorretention. They are designed to provide resistance to both gasoline andoils, as well as a high level of impact strength at temperatures down to−40° C. In particular, high modulus ductile (HMD) XENOY™ polymers aredesirable due to their balance of high stiffness and ductility.Thermoformed XENOY™ allows for reduced packaging space compared to TPOand EPP, for example. Fillers (glass, mineral etc.) can be used toincrease the modulus of a polymer. However, the addition of fillerusually reduces the ductility of the polymer (as measured by elongationat break and yield in ASTM D638 tensile strain measurements). XENOY™ HMDpolymers have a secondary nano-fibrillated network which enables the useof fillers to increase modulus, while still maintaining the highelongation at break of unfilled polymer that is beneficial to absorbenergy. The ductility of HMD polymers is also increased significantly,as measured by notched Izod impact tests (ASTM D256). HMD polymers alsoprovide better creep and tensile fatigue performance. These HMD polymersallow the walls of the beam to be thinner, due to the increased modulus,while still maintaining their structure in typical automotive crash testscenarios. XENOY™ X4820 can be a desirable polymer due to its balance ofhigh stiffness and ductility. The bumper beam can be formed fromcombinations including at least one of any of the above-describedmaterials.

Bumper systems including beams of the present disclosure can satisfyR-CAR standards, including for example low speed damageability insurancetests such as R-CAR Section 0031, and/or ECE-R42 criteria, such as lowspeed damageability regulation ECE-42 Section 0031. A bumper systemincluding a beam of the present disclosure can absorb a corner impact at2.5 kilometers per hour (kph) when coupled to a vehicle weighing 500 to2,000 kg, for example, 900 to 1,600 kg, with an intrusion of less thanor equal to 140 mm. The beams of the present disclosure can have higherstiffness than conventional beams, and can have lower levels ofintrusion. A bumper system including a beam of the present disclosurecan absorb a center pendulum impact at 4 kph when coupled to a vehicleweighing 500 to 2,000 kg, for example, 900 to 1,600 kg, with anintrusion of less than or equal to 140 mmA bumper system including abeam of the present disclosure can absorb an outboard impact at 4 kphwhen coupled to a vehicle weighing 500 to 2,000 kg, for example, 900 to1,600 kg, with an intrusion of less than or equal to 140 mm.

In the RCAR 40% overlap impact test at 16 kph, the maximum forcemeasured must be less than or equal to 110 kiloNewtons (kN). A bumpersystem including a beam of the present disclosure meet the RCAR 40%overlap impact test at 16 kph with a maximum force measured of less thanor equal to 100 kN, for example, less than or equal to 90 kN, forexample, less than or equal to 80 kN, for example, less than or equal to70 kN.

The following examples are merely illustrative of the beams disclosedherein and are not intended to limit the scope hereof. Unless otherwisestated, all examples were based upon simulations.

EXAMPLES Example 1

LS-DYNA software was used for all the simulations and XENOY™ resin 1103commercially available from SABIC's Innovative Plastics business wasused as the material. In this example, Sample 1 is a beam of the designdepicted in FIG. 7 that is tested in ECE R42 simulations. ECE R42specifies no failure of expensive parts for ECE R42 pendulum impacts.Expensive parts can include the beam, fascia, vehicle rails, etc. Thebeam is as previously described herein and includes a box section and atriangular section. In Sample 1, the walls and ribs of the beam all havea thickness of 2.5 mm. The beam is composed of XENOY™ and weighs 2.34kg. The vehicle mass used in the simulations is approximately 902 kg.The beam is subjected to a center pendulum impact test, an outboardpendulum impact test, and a corner pendulum impact test in accordancewith ECE R42.

FIG. 11A depicts a top perspective view illustrating the relativeposition of a pendulum 50 in an ECE R42 center pendulum impact test. Inthis center pendulum impact test, the pendulum 50 applies a force F of4.0 kph to beam 10 at the outer surface 14 at the location of thecentral area midpoint 32. The results of this test demonstrate a highlylocalized maximum strain of 20% at the central area midpoint (i.e., thebeam center). Also observed is that the failure strain of the materialis greater than 80% and no back panel deformation is observed. FIGS. 12Aand 12B are graphical representations of the results of the centerpendulum impact test. FIG. 12A shows the force in kiloNewtons (kN)versus time in miliseconds (ms). As can be seen in FIG. 12A, the maximumforce is approximately 10 kN and occurs at about 100 ms, after which theforce decreases. FIG. 12B shows fascia intrusion in mm versus time inms. As can be seen in FIG. 12B, the maximum fascia intrusion isapproximately 47 mm and occurs at approximately 100 ms, after which theintrusion decreases.

FIG. 11B is a top perspective view depicting the relative position of apendulum 50 in an ECE R42 outboard pendulum impact test. In thisoutboard pendulum impact test, the pendulum 50 applies a force F of 4.0kph to beam 10 at a pendulum midpoint 52 that is located a distance Yfrom the central area midpoint 32, wherein Y is equal to 300 mm. Theresults of this test demonstrate a highly localized maximum strain of39% at the central area midpoint (i.e., the beam center). Alsodemonstrated by this test is that the failure strain of the material isgreater than 80%. Further, no back panel deformation is observed. FIGS.13A and 13B are graphical representations of the results of the outboardpendulum impact test. FIG. 13A shows the force (kN) versus time (ms). Ascan be seen in FIG. 13A, the maximum force occurs at approximately 70 msand is approximately 19 kN. FIG. 13B shows fascia intrusion (mm) versustime (ms). As can be seen in FIG. 13B, the maximum fascia intrusion isapproximately 19 mm and occurs at approximately 75 ms, after which theintrusion decreases.

FIG. 11C is a top perspective view depicting the position of a pendulum50 in an ECE R42 corner pendulum impact test. In this corner pendulumimpact test, pendulum 50 applies a force F of 2.5 kph to the beam 10 atbeam corner 54. FIGS. 14A and 14B are graphical representations of theresults of the corner pendulum impact test. FIG. 14A shows the force inkN versus time in ms. As can be seen in FIG. 14A, the maximum force isapproximately 9 kN at approximately 100 ms. FIG. 14B shows fasciaintrusion in mm versus time in ms. As can be seen in FIG. 14B, themaximum fascia intrusion is approximately 8 mm occurring at about 120ms, after which time the maximum intrusion decreased.

The results of the center pendulum impact, outboard pendulum impact, andcorner impact demonstrate that a beam having the design disclosure inFIG. 7 performs well in ECE R42 tests with minimal damage to componentsof the vehicle. An advantageous result observed from the testillustrates that no plastic strain is observed in the inner surface ofthe beam for the center pendulum impact.

Example 2

In this example, Sample 2 is a beam of the design shown in FIG. 7 thatis subjected to a simulated RCAR test. The beam is as previouslydescribed herein with respect to FIG. 7 and includes a box section and atriangular section. In Sample 2, the walls and ribs of the beam all havea thickness of 2.5 mm. The beam is composed of XENOY™ and weighs 2.34kg. The vehicle mass is approximately 902 kg. In this RCAR simulation,RCAR regulations provide that a maximum force should not exceed 110 kNduring a 16 kph RCAR 40% overlap impact. During the simulation of Sample2, it is observed that less than half of the total depth of the end area(e.g., crash can) is crushed. Slight deformation of the inner surface isobserved, but the outer surface of the end area does not display majordeformation. The deformation is within the acceptable limits. FIG. 15 isa graphical illustration of the cross-section force in kN versus time inms in the RCAR 40% overlap test. In the RCAR test in Sample 2, the beamdisplays a maximum force of approximately 63 kN and a maximum intrusionof approximately 120 mm. Thus, the beam absorbs a significant amount ofenergy, therefore desirably displaying low levels of force less than orequal to 63 kN.

The beams disclosed herein can meet the requirements set forth byvarious regulations for vehicles. For example, the beams disclosedherein can absorb a large amount of energy such that force levelsexperienced by the beam are less than or equal to 63 kN during RCARtests, which is nearly 50% less than allowed under the regulation of 110kN. The beams disclosed herein can provide increased surface area at theend areas of the beam in order to provide further energy absorbingcapabilities to the beam. The use of box sections can impart reducedweight and maintain stiffness of the beam to pass the requirements setforth by the ECR 42 impacts. The use of triangular sections can impartreduced weight and maintain stiffness of the beam to pass therequirements set forth by the ECR 42 impacts. The use of box sectionsand triangular sections can impart reduced weight and maintain stiffnessof the beam to pass the requirements set forth by the ECR 42 impacttest. For example, the beams disclosed herein can have no plastic strainin the outer surface of the beam during the center pendulum impact test,which is an important impact test in ECE R42.

The beams and bumper systems disclosed herein include at least thefollowing aspects:

Aspect 1: A beam configured to couple to a vehicle, comprising: a firstend area comprising a first end midpoint equidistant from a top face anda bottom face on a vertical axis when the beam is positioned on thevehicle; a second end area comprising a second end midpoint equidistantfrom the top face and the bottom face on the vertical axis when the beamis positioned on the vehicle; a central area positioned between thefirst end area and the second end area, the central area having acentral area midpoint that is equidistant from the top face and thebottom face on the vertical axis when the beam is positioned on thevehicle 38 and that is positioned in the center of the beam along alongitudinal axis; an inner surface; and an outer surface; wherein thelongitudinal axis of the beam passes through the first end area and thesecond end area; wherein the central area is capable of rotating aboutthe longitudinal axis when the beam is impacted by an applied force.

Aspect 2: The beam according to Aspect 1, wherein a cross-sectionportion of the beam taken along a line from the inner surface to theouter surface varies along the length of the beam.

Aspect 3: The beam according to any of Aspects 1-2, wherein the centralarea comprises a cross-sectional geometry comprising a box section, atriangular section, or a combination comprising at least one of theforegoing.

Aspect 4: The beam according to any of the preceding aspects, whereinthe central area is vertically offset from the end areas.

Aspect 5: The beam according to any of the preceding aspects, whereinthe beam has a width that varies along the length of the beam.

Aspect 6: The beam according to any of the preceding aspects, wherein atleast one end area has a greater width than the width of the centralarea when measured from the inner surface to the outer surface at apoint along the longitudinal axis.

Aspect 7: A beam configured to couple to a vehicle, comprising: a firstend area comprising a first end midpoint equidistant from the top faceand the bottom face on a vertical axis when the beam is positioned onthe vehicle; a second end area comprising a second end midpointequidistant from the top face and the bottom face on the vertical axiswhen the beam is positioned on the vehicle; a central area positionedbetween the first end area and the second end area, the central areahaving a central area midpoint that is equidistant from the top face andthe bottom face on the vertical axis when the beam is positioned on thevehicle; wherein the longitudinal axis of the beam passes through thefirst end area and the second end area, and optionally a fasciapositioned to substantially envelop the beam; wherein a cross-section ofthe beam taken along a line from the inner surface to the outer surfacevaries along the length of the beam.

Aspect 8: The beam according to Aspect 7, wherein the central area iscapable of rotating about a longitudinal axis when the beam is impactedby an applied force.

Aspect 9: The beam according to any of the preceding aspects, whereinthe beam comprises a thermoplastic polymer, a glass mat thermoplasticpolymer, a thermoset, a composite, a metallic material, a metallicplastic hybrid, or a combination comprising at least one of theforegoing.

Aspect 10: The beam according to Aspect 9, wherein the beam comprises athermoplastic polymer.

Aspect 11: The beam according to Aspect 10, wherein the thermoplasticpolymer is selected from acrylonitrile-butadiene-styrene; polybutyleneterephthalate; polycarbonate; copolycarbonate-polyesters;acrylic-styrene-acrylonitrile; acrylonitrile-(ethylene-polypropylenediamine modified)-styrene; phenylene ether polymers; polyamides;phenylene sulfide polymers; polyvinyl chloride; polystyrene;polyethylene; polypropylene; thermoplastic olefins, or a combinationcomprising at least one of the foregoing.

Aspect 12: The beam according to Aspect 11, wherein the thermoplasticpolymer is a blend of polycarbonate and polybutylene terephthalate.

Aspect 13: The beam according to any of the preceding aspects, whereinthe beam is configured to attach to a rear of a vehicle to absorb energyupon impact.

Aspect 14: The beam according to any of the preceding aspects, whereinthe beam is configured to attach to a front of a vehicle to absorbenergy upon impact.

Aspect 15: A bumper system comprising: a beam according to any of thepreceding aspects; and optionally, a fascia.

Aspect 16: The bumper system of Aspect 15, wherein the beam comprises athermoplastic polymer, a glass mat thermoplastic polymer, a thermoset, acomposite, a metallic material, a metal plastic hybrid, or a combinationcomprising at least one of the foregoing.

Aspect 17: The bumper system of any of Aspects 15-16, wherein the systemis a front bumper system.

Aspect 18: The bumper system of any of Aspects 15-17, wherein the systemis a rear bumper system.

Aspect 19: The bumper system of any of Aspects 15-18, wherein the systemis a front underrun protection system.

Aspect 20: The bumper system of any of Aspects 15-19, wherein thecentral area comprises a cross-sectional geometry comprising a boxsection, a triangular section, or a combination comprising at least oneof the foregoing.

In general, the invention may alternately comprise, consist of, orconsist essentially of, any appropriate components herein disclosed. Theinvention may additionally, or alternatively, be formulated so as to bedevoid, or substantially free, of any components, materials,ingredients, adjuvants or species used in the prior art compositions orthat are otherwise not necessary to the achievement of the functionand/or objectives of the present invention. The endpoints of all rangesdirected to the same component or property are inclusive andindependently combinable (e.g., ranges of “less than or equal to 25 wt%, or 5 wt % to 20 wt %,” is inclusive of the endpoints and allintermediate values of the ranges of “5 wt % to 25 wt %,” etc.).Disclosure of a narrower range or more specific group in addition to abroader range is not a disclaimer of the broader range or larger group.“Combination” is inclusive of blends, mixtures, alloys, reactionproducts, and the like. Furthermore, the terms “first,” “second,” andthe like, herein do not denote any order, quantity, or importance, butrather are used to denote one element from another. The terms “a” and“an” and “the” herein do not denote a limitation of quantity, and are tobe construed to cover both the singular and the plural, unless otherwiseindicated herein or clearly contradicted by context. “Or” means“and/or.” The suffix “(s)” as used herein is intended to include boththe singular and the plural of the term that it modifies, therebyincluding one or more of that term (e.g., the film(s) includes one ormore films). Reference throughout the specification to “one embodiment”,“another embodiment”, “an embodiment”, and so forth, means that aparticular element (e.g., feature, structure, and/or characteristic)described in connection with the embodiment is included in at least oneembodiment described herein, and may or may not be present in otherembodiments. In addition, it is to be understood that the describedelements may be combined in any suitable manner in the variousembodiments.

The modifier “about” used in connection with a quantity is inclusive ofthe stated value and has the meaning dictated by the context (e.g.,includes the degree of error associated with measurement of theparticular quantity). The notation “±10%” means that the indicatedmeasurement can be from an amount that is minus 10% to an amount that isplus 10% of the stated value. The terms “front”, “back”, “bottom”,and/or “top” are used herein, unless otherwise noted, merely forconvenience of description, and are not limited to any one position orspatial orientation. “Optional” or “optionally” means that thesubsequently described event or circumstance can or cannot occur, andthat the description includes instances where the event occurs andinstances where it does not. Unless defined otherwise, technical andscientific terms used herein have the same meaning as is commonlyunderstood by one of skill in the art to which this invention belongs. A“combination” is inclusive of blends, mixtures, alloys, reactionproducts, and the like.

Unless otherwise specified herein, any reference to standards,regulations, testing methods and the like, such as RCAR and ECE R42refer to the standard, regulation, guidance or method that is in forceat the time of filing of the present application.

All cited patents, patent applications, and other references areincorporated herein by reference in their entirety. However, if a termin the present application contradicts or conflicts with a term in theincorporated reference, the term from the present application takesprecedence over the conflicting term from the incorporated reference

While particular embodiments have been described, alternatives,modifications, variations, improvements, and substantial equivalentsthat are or may be presently unforeseen may arise to applicants orothers skilled in the art. Accordingly, the appended claims as filed andas they may be amended are intended to embrace all such alternatives,modifications variations, improvements, and substantial equivalents.

I/we claim:
 1. A beam configured to couple to a vehicle, comprising: afirst end area comprising a first end midpoint equidistant from a topface and a bottom face on a vertical axis when the beam is positioned onthe vehicle; a second end area comprising a second end midpointequidistant from the top face and the bottom face on the vertical axiswhen the beam is positioned on the vehicle; a central area positionedbetween the first end area and the second end area, the central areahaving a central area midpoint that is equidistant from the top face andthe bottom face on the vertical axis when the beam is positioned on thevehicle and that is positioned in the center of the beam along alongitudinal axis; an inner surface; and an outer surface; wherein thelongitudinal axis of the beam passes through the first end area and thesecond end area; wherein the central area is capable of rotating aboutthe longitudinal axis when the beam is impacted by an applied force. 2.The beam according to claim 1, wherein a cross-section portion of thebeam taken along a line from the inner surface to the outer surfacevaries along the length of the beam.
 3. The beam according to claims 1,wherein the central area comprises a cross-sectional geometry comprisinga box section, a triangular section, or a combination comprising atleast one of the foregoing.
 4. The beam according to claim 1, whereinthe central area is vertically offset from the end areas.
 5. The beamaccording to claim 1, wherein the beam has a width that varies along thelength of the beam.
 6. The beam according to claim 1, wherein at leastone end area has a greater width than the width of the central area whenmeasured from the inner surface to the outer surface at a point alongthe longitudinal axis.
 7. A beam configured to couple to a vehicle,comprising: a first end area comprising a first end midpoint equidistantfrom the top face and the bottom face on a vertical axis when the beamis positioned on the vehicle; a second end area comprising a second endmidpoint equidistant from the top face and the bottom face on thevertical axis when the beam is positioned on the vehicle; a central areapositioned between the first end area and the second end area, thecentral area having a central area midpoint that is equidistant from thetop face and the bottom face on the vertical axis when the beam ispositioned on the vehicle; wherein the longitudinal axis of the beampasses through the first end area and the second end area; andoptionally, a fascia positioned to substantially envelop the beam;wherein a cross-section of the beam taken along a line from the innersurface to the outer surface varies along the length of the beam.
 8. Thebeam according to claim 7, wherein the central area is capable ofrotating about a longitudinal axis when the beam is impacted by anapplied force.
 9. The beam according to claim 1, wherein the beamcomprises a thermoplastic polymer, a glass mat thermoplastic polymer, athermoset, a composite, a metallic material, a metallic plastic hybrid,or a combination comprising at least one of the foregoing.
 10. The beamaccording to claim 9, wherein the beam comprises a thermoplasticpolymer.
 11. The beam according to claim 10, wherein the thermoplasticpolymer is selected from acrylonitrile-butadiene-styrene; polybutyleneterephthalate; polycarbonate; copolycarbonate-polyesters;acrylic-styrene-acrylonitrile; acrylonitrile-(ethylene-polypropylenediamine modified)-styrene; phenylene ether polymers; polyamides;phenylene sulfide polymers; polyvinyl chloride; polystyrene;polyethylene; polypropylene; thermoplastic olefins, or a combinationcomprising at least one of the foregoing.
 12. The beam according toclaim 11, wherein the thermoplastic polymer is a blend of polycarbonateand polybutylene terephthalate.
 13. The beam according to claim 1,wherein the beam is configured to attach to a rear of a vehicle toabsorb energy upon impact.
 14. The beam according to claim 1, whereinthe beam is configured to attach to a front of a vehicle to absorbenergy upon impact.
 15. A bumper system comprising: a beam according toclaim 1; and optionally a fascia.
 16. The bumper system of claim 15,wherein the beam comprises a thermoplastic polymer, a glass matthermoplastic polymer, a thermoset, a composite, a metallic material, ametal plastic hybrid, or a combination comprising at least one of theforegoing.
 17. The bumper system of claim 15, wherein the system is afront bumper system.
 18. The bumper system of claim 15, wherein thesystem is a rear bumper system.
 19. The bumper system of claim 15,wherein the system is a front underrun protection system.
 20. The bumpersystem of claim 15, wherein the central area comprises a cross-sectionalgeometry comprising a box section, a triangular section, or acombination comprising at least one of the foregoing.